Maintenance alert system for heavy-duty trucks

Abstract

A real-time maintenance alert system and method for use in a heavy-duty truck having an engine controller with memory are provided. The system includes a sensor operative to indicate an engine condition from the group consisting of: oil filter restriction, air filter restriction, fuel filter restriction, oil level, and coolant reserve tank fluid level. Control logic at the engine controller processes the sensor signal to determine a real-time fault condition, when appropriate.

Description

TECHNICAL FIELD

The present invention relates to a real-time maintenance alert system for use in a heavy-duty truck having an engine controller with memory.

BACKGROUND ART

In the control of fuel injection systems, electronic control units having volatile and non-volatile memory, input and output driver circuitry, and a processor capable of executing a stored instruction set are utilized to control various functions of the engine and its associated systems. A particular electronic control unit communicates with numerous sensors, actuators, and other electronic control units necessary to control various functions, which may include various aspects of fuel delivery, transmission control, or many others.

In heavy-duty truck applications, in addition to utilizing a highly complex engine controller that monitors the engine conditions so that when required, engine protection and engine shutdown logic may be executed to prevent possible engine damage, some normal service items of a truck must be physically inspected by opening the hood to physically check each item, preferably each time the truck is stopped. With the heavy-duty trucking industry becoming more and more competitive, maintenance reduction is becoming significantly more important. As such, it is sometimes undesirably time consuming to tilt the hood and physically check each normal service item of each truck throughout the day at a trucking bay.

For the foregoing reasons, there is a need for a system that facilitates the checking of normal service items of a truck.

DISCLOSURE OF INVENTION

It is therefore an object of the present invention to provide a real-time maintenance alert system for use in a heavy-duty truck that allows normal service items of a truck to be checked at a glance, rather than opening the hood to physically check each item.

In carrying out the above object and other objects and features of the present invention, a real-time maintenance alert system for use in a heavy-duty truck having an engine and engine controller with memory is provided. The system comprises a sensor operative to produce a signal indicative of a least one engine condition from the group consisting: an oil filter restriction condition, a fuel filter restriction condition, an air filter restriction condition, an oil level, and a coolant level in a coolant reserve tank. The system further comprises control logic at the engine controller. The control logic is configured to process the sensor signal and to determine a real-time fault condition when the engine condition falls outside of a predetermined acceptable range. The control logic is further operative to produce an output signal in response to the real-time fault condition.

In a preferred embodiment, a display device receives the control logic output signal; and, the display device has an indicator operative to alert a user of the real-time fault condition.

Further, in carrying out the present invention, a real-time maintenance alert method for use in a heavy-duty truck having an engine and an engine controller with memory is provided. The method comprises generating a signal with an engine sensor, and processing the signal with control logic at the engine controller. The signal indicates at least one engine condition from the group consisting of: an oil filter restriction condition, a fuel filter restriction condition, an air filter restriction condition, an oil level, and a coolant level at a coolant reserve tank. The signal is processed to determine a real-time fault condition when the engine condition falls outside of a predetermined acceptable range. The control logic is further operative to produce an output signal in response to the real-time fault condition. Preferably, the method further comprises generating an alert signal on a display device to alert a user of the real-time fault condition when such condition is present.

Still further, in carrying out the present invention, a display device for use with a real-time maintenance alert system for a heavy-duty truck having and an engine controller with memory is provided. The display device comprises a housing, an interface, and an indicator device. The interface is configured to communicate with control logic at the engine controller. The control logic is configured to process a sensor signal indicative of an engine condition from the group consisting: an oil filter restriction condition, a fuel filter restriction condition, an air-filter restriction condition, an oil level, and a coolant level in a coolant reserve tank. The control logic is further configured to determine a real-time fault condition when the engine condition falls outside of a predetermined acceptable range. The control logic is further operative to produce an output signal in response to the real-time fault condition. The interface receives the output signal.

The indicator device is affixed to the housing and communicates with the interface. The indicator device produces a visual indication when the output signal corresponding to the real-time fault condition is received at the interface.

The advantages associated with the embodiments of the present invention are numerous. For example, embodiments of the present invention allow normal service items of a truck to be checked at a glance rather than requiring opening of the hood to physically check each item. Further, preferably, control logic for the real-time maintenance alert system operates independently of any existing engine protection or engine shutdown control logic. That is, the maintenance alert system control logic provides an indication when normal service items require maintenance. It is to be appreciated that the maintenance alert system embodiments of the present invention alert a user of a real-time fault condition, based on a sensor measurement, as opposed to based on the passage of time or distance as measured by the odometer since a previous maintenance operation.

The above object and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best mode for carrying out the invention when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a fuel injection system made in accordance with the present invention;

FIG. 2 is a functional block diagram illustrating a real-time maintenance alert system for a heavy-duty truck and associated methods used by the system;

FIG. 3 is a block diagram illustrating a real-time maintenance alert method of the present invention;

FIG. 4 is a display device of the present invention for use in a real-time maintenance alert system;

FIG. 5 is an alternative display device of the present invention for use with a real-time maintenance alert system.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring to FIG. 1, a system for controlling a heavy duty truck is shown. The system, generally indicated by reference numeral 10, includes an engine 12 having a plurality of cylinders, fed by fuel injectors. In a preferred embodiment, engine 12 is a compression-ignition internal combustion engine, such as a four, six, eight, twelve, sixteen or twenty-four cylinder diesel engine, or a diesel engine having any other desired number of cylinders. The fuel injectors are receiving pressurized fuel from a supply connected to one or more high or low pressure pumps (not shown) as is well known in the art. Alternatively, embodiments of the present invention may employ a plurality of unit pumps (not shown), with each pump supplying fuel to one of the injectors.

The system 10 may also include various sensors 20 for generating signals indicative of corresponding operational conditions or parameters of engine 12, the vehicle transmission (not shown), and other vehicular components. Sensors 20 are in electrical communication with a controller 22 via signal

where:

• X is the MID of the requestor,
• Y is an ECM Unique ID desired,
• Q is another ECM Unique ID if desired,
  If ECM Unique ID 66 and 67 was requested, the response would look like:
  128 254 Z 66 V 67 W

where:

• Z is either the MID of the requester or the MID of the last device on the system to make an ECM Unique ID request, and V and W are additional data.
  Normal Operation

Once the maintenance alert system is in the normal operating mode (passive listening), the system monitors fault codes from both the engine ECM and the maintenance sensors. Each fault code received about the maintenance sensors will only effect the status of one LED. The LEDs for the levels and the filters will only turn red for service if the fluid is low or the filter restriction is high.

In one suitable indicator configuration using LEDs, the LED functioning is as follows:

LED 1, “Ign Key On”

The function of this light is to inform the operator when the display is showing memory data rather than current data. This LED will use the +5V sensor supply input wire. The LED will be:

• • RED—Sensor supply voltage input grounded Memory Data).
  • OFF—Sensor supply voltage input at +5V (Current Data).
    LED 2, “Oil Level”

The oil level LED will be:

• • RED—Oil Level PID 98 FMI 1 only (Engine Oil Level Low).
  • GREEN—Oil Level PID 98 received without fault codes for PID 98.
  • YELLOW (drive both red and green)—Oil Level PID 98 not received even though configured.
  • OFF—Oil level not configured OR fault codes for PID 98 other than FMI 0 1.
    LED 3, “Oil Filter”

The oil filter LED will be:

• • RED—Oil filter restriction PID 99 FMI 0 only (Primary Oil Filter Restriction High).
  • GREEN—Oil filter restriction PID 99 received without fault codes for PID 99.
  • OFF—Oil filter restriction not configured OR fault codes for PID 99 other than FMI 0.
    LED 4, “Coolant Level”

The coolant level LED will be:

• • RED—Coolant level PID 111 FMI 1 only (Coolant level low).
  • GREEN—Coolant level PID 111 received without fault codes for PID 111.
  • OFF—Coolant level not configured OR fault codes for PID 111 other than FMI 1.
    LED 5, “Air Filter”

The air filter restriction LED will be:

• • RED—Air filter restriction PID 107 FMI 0 only (Air Filter Restriction High).
  • GREEN—Air filter restriction PID 107 received without fault codes for PID 107.
  • OF—Air filter restriction not configured OR fault codes for PID 107 other than FMI 0.
    LED 6, “DDEC Codes” (Protection Faults)

The ECM codes LED is intended to assist service personnel by indicating the presence of fault codes in the ECM.

The ECM Codes LED will be:

• • RED—The presence of any active fault code from MID 128.
  • Yellow—The presence of only inactive fault codes from MID 128.
  • GREEN—No fault codes from MID 128.
    LED 7, “Fuel Filter”

The fuel filter restriction LED will be:

• • RED—Fuel filter restriction PID 95 FMI 0 only (Primary Fuel Filter Restriction High).
  • GREEN—Fuel filter restriction PID 95 received without fault codes for PID 95.
  • OFF—Fuel filter restriction not configured OR fault codes for PID 95 other than FMI 0.
    LED 8, “DDEC Reports—PM” (Periodic Maintenance)

The Data Pages portion of the ECM has three preventative maintenance reminders normally to be accessed through the DDEC Reports Software package. An ECM unique message will be used and can be requested to show the configuration/status of the PM reminders. This message will be one byte in length with the capability of showing the status of four PM reminders (possibly future ECM expansion) and needs to be requested at each test sequence, but use the data from memory if the ECM is not powered.

The message identifier and format will be:

ECM Unique ID 67

• • Bits 8, 7: Not Defined—Set to 11 (Not Configured)
  • Bits 6, 5: PM C
    • 00-Configured, No Service Needed
    • 01-Configured, Service Needed
    • 11-Not Configured
  • Bits 4, 3: PM B
    • 00-Configured, No Service Needed
    • 01-Configured, Service Needed
    • 11-Not Configured
  • Bits 2, 1: PM A
    • 00-Configured, No Service Needed
    • 01-Configured, Service Needed
    • 11-Not Configured

The DDEC Reports LED will be:

• • RED—Any one or more of the PM reminders is configured and needs service.
  • GREEN—None of the configured PM reminders need service.
  • OFF—None of the PM reminders are configured.

Preferably, the display unit is mounted inside the truck cab on the floor beside the driver's seat for easy viewing and access while standing outside the truck with the driver's door open. The case of the display should then have easy mounting to the floor either directly or via a suitable bracket thus making for easy viewing conditions while standing just outside the door. This mounting location also necessitates that the case be made of a reasonably sturdy material to prevent damage if bumped with a hammer, fire extinguisher, etc. The display should be sealed for the occasional cleaning of the cab via water hose and a have a −40 to 85 degree Celsius temperature range. The products used preferably also are built to withstand the normal cleaning fluids and other materials found inside a truck just as the main instrument panel must.

While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.

Claims

1. A real-time maintenance alert system for use in a heavy duty truck having an engine including an air filter at an air inlet, and an engine controller having a communications data link and, the system comprising:

a sensor operative to produce a signal indicative of an air inlet depression;

control logic at the engine controller, the control logic being conjured configured to process the sensor signal and to determine an air filter restriction real-time fault condition when the air inlet depression falls below a threshold, the control logic being operative to produce an output signal at the data link in response to the air filter restriction real-time fault condition; and

a display device having a memory and configured to transmit and receive information over the data link, the display processing the output signal and storing a status of the air filter in the memory, and generating an output signal indicative of the status.

2. The system of claim 1 wherein the threshold is a function of an engine rpm.

3. The system of claim 2 wherein the threshold is a first value when the engine rpm is less than a predetermined value and, otherwise, the threshold is a second value.

4. The system of claim 1 wherein the air filter restriction real-time fault condition is determined in response to the air inlet depression falling below the threshold more than one time during a predetermined time interval.

5. A real-time maintenance alert system for use in a heavy duty truck having an engine including a fuel filter at a fuel inlet, and an engine controller having a communications data link and, the system comprising:

a sensor operative to produce a signal indicative of a fuel inlet depression;

control logic at the engine controller, the control logic being configured to process the sensor signal and to determine a fuel filter restriction real-time fault condition when the fuel inlet depression falls below a threshold, the control logic being operative to produce an output signal at the data link in response to the fuel filter restriction real-time fault condition; and

a display device having a memory and configured to transmit and receive information over the data link, the display device processing the output signal and storing a status of the fuel filter in the memory, and generating an output signal indicative of the status.

6. A real-time maintenance alert system for use in a heavy duty truck having an engine including an oil filter having an inlet and an outlet, and an engine controller having a communications data link and, the system comprising:

a sensor operative to produce a signal indicative of an oil filter pressure differential between the oil filter inlet and the oil filter outlet;

control logic at the engine controller, the control logic being configured to process the sensor signal and to determine an oil filter restriction real-time fault condition when the oil filter pressure differential exceeds a threshold, the control logic being operative to produce an output signal at the data link in response to the oil filter restriction real-time fault condition; and

a display device having a memory and configured to transmit and receive information over the data link, the display device processing the output signal and storing a status of the oil filter in the memory, and generating an output signal indicative of the status.

7. A real-time maintenance alert system for use in a heavy duty truck having an engine including an oil pan, and an engine controller having a communications data link and, the system comprising:

a sensor operative to produce a signal indicative of an oil level;

control logic at the engine controller, the control logic being configured to process the sensor signal and to determine a low oil real-time fault condition when the oil level falls below a threshold, the control logic being operative to produce an output signal at the data link in response to the oil level real-time fault condition; and

a display device having a memory and configured to transmit and receive information over the data link, the display device processing the output signal and storing a status of the oil level in the memory, and generating an output signal indicative of the status.

8. The system of claim 7 wherein the low oil real-time fault condition is determined in response to the oil level falling below the threshold while the engine is not running.

9. The system of claim 8 wherein the low oil real-time fault condition is determined in response to the oil level being below the threshold while the engine is not running and has not been running for a predetermined time interval.

10. A real-time maintenance alert system for use in a heavy duty truck having an engine including a coolant reserve tank, and an engine controller having a communications data link and, the system comprising:

a sensor operative to produce a signal indicative of a coolant level;

control logic at the engine controller, the control logic being configured to process the sensor signal and to determine a low coolant real-time fault condition when the coolant level falls below a threshold, the control logic being operative to produce an output signal at the data link in response to the low coolant real-time fault condition, wherein the threshold is sufficiently high such that engine shutdown is not required upon the presence of the low coolant real-time fault condition; and

a display device having a memory and configured to transmit and receive information over the data link, the display device processing the output signal and storing a status of the coolant reserve tank in the memory, and generating an output signal indicative of the status.

11. The system of claim 10 further comprising:

a primary coolant level sensor operative to produce a signal indicative of a sufficiently low coolant level to demand engine shutdown, wherein the control logic is further configured to determine an engine shutdown fault upon the presence of the primary coolant level sensor signal.

12. A real-time maintenance alert system for use in a heavy duty truck having an engine, and an engine controller having a communications data link, the system comprising:

a sensor operative to produce a signal indicative of at least one engine condition from the group consisting of: an oil filter restriction condition, a fuel filter restriction condition, an air filter restriction condition, an oil level, and a coolant level in a coolant reserve tank;

control logic at the engine controller, the control logic being configured to process the sensor signal and to determine a real-time fault condition when the engine condition falls outside of a predetermined acceptable range, the control logic being operative to produce an output signal at the data link in response to the real-time fault condition; and

a display device having memory and configured to transmit and receive information over the data link, the display device processing the output signal and storing a fault condition status in the memory, the display device having an indicator operative to alert a user of the real-time fault condition.

13. A real-time maintenance alert method for use in a heavy duty truck having an engine, and an engine controller having a communications data link and, the method comprising:

generating a signal with an engine sensor, the signal being indicative of at least one engine condition from the group consisting of: an oil filter restriction condition, a fuel filter restriction condition, an air filter restriction condition, an oil level, and a coolant level in a coolant reserve tank;

processing the signal with control logic at the engine controller to determine a real-time fault condition when the engine condition falls outside of a predetermined acceptable range, the control logic being operative to produce an output signal at the data link in response to the real-time fault condition;

receiving the output signal over the data link at a display device having a memory; and

storing a fault condition status in the memory.

14. The method of claim 13 further comprising:

generating an alert signal on the display device to alert a user of the real-time fault condition.

15. A display device for use with a real-time maintenance alert system for a heavy duty truck having an engine and an engine controller having a communications data link, the display device comprising:

a housing;

an interface configured to communicate with control logic at the engine controller over the data link, the control logic being configured to process a sensor signal indicative of an engine condition from the group consisting of: an oil filter restriction condition, a fuel filter restriction condition, an air filter restriction condition, an oil level, and a coolant level in a coolant reserve tank, and the control logic being further configured to determine a real-time fault condition when the engine condition falls outside of a predetermined acceptable range, the control logic being operative to produce an output signal at the data link in response to the real-time fault condition, the interface receiving the output signal;

a memory for storing a fault condition status based on the output signal; and

an indicator device affixed to the housing and in communication with the interface, the indicator device producing a visual indication when the output signal corresponding to the real-time fault condition is received at the interface.

16. The display device of claim 15 wherein the control logic is further configured with engine protection shutdown logic operative to provide an engine protection fault condition signal to the interface, the display device further comprising:

an engine protection indicator device affixed to the housing and in communication with the interface, the engine protection indicator device producing a visual indication when the output signal corresponding to the engine protection fault condition is received at the interface.

17. The display device of claim 15 wherein the control logic is further configured with periodic maintenance logic operative to provide a periodic maintenance fault condition signal to the interface, the display device further comprising:

a periodic maintenance indicator device affixed to the housing and in communication with the interface, the periodic maintenance indicator device producing a visual indication when the output signal corresponding to the periodic maintenance fault condition is received at the interface.

18. The display device of claim 15 further comprising:

a reset switch in communication with the interface, wherein the interface and the control logic are configured such that assertion of the reset switch causes a refreshing of the sensor signal.

19. The display device of claim 15 further comprising:

a test switch in communication with the indicator device, wherein the indicator device is configured to produce the visual indication for a predetermined period of time in response to assertion of the test switch.

20. The display device of claim 15 wherein the indicator device comprises:

a light emitting diode.